Condensate sensor enclosure

ABSTRACT

A condensate sensor enclosure to house an electromechanical control system to limit the level of condensate within a drain pan of an air conditioning system comprising a control system compartment and cover coupled together by a coupling assembly including a first coupler and a second coupler to enclose the electromechanical control system therein and a pair of probe housings each extending downwardly from the bottom of the control system compartment to operatively receive and house at least a portion a corresponding pair of electrically conductive sensor probes operatively coupled to the electromechanical control system to sense when the condensate within the drain pan reaches a predetermined level.

FIELD OF THE INVENTION

The present invention relates to a condensation sensor enclosure to house an electromechanical control system to limit the level of condensate within a drain pan of an air conditioner.

DESCRIPTION OF THE PRIOR ART

Air handling systems such as air conditioning systems typically have a condensate collector or drain pan to collect condensate. If left without a means of controlling the level or volume of condensate within the condensation collector or drain pan, there is often an overflow of condensate from the collection or drain pan causing damage to the house or building.

To mitigate this danger, condensate can be removed from the condensate collector or drain pan by the use of a pump. To accomplish this, a drain pan system including a sensor is placed in the drain pan to sense the level of the condensation therein. When the condensate level reaches a predetermined level, the sensor generates a signal sent to a sensor switching circuit to activate the pump to prevent the condensate from overflowing the drain pan. In addition, the air handling system may be shut down to prevent the creation or generation of more condensate.

Although a seemingly limitless number of such systems exist, there remains a need for a reliable condensate sensor system adequately isolated from the operating environs by a protective enclosure or housing.

SUMMARY OF THE INVENTION

The present invention relates to a condensation sensor enclosure to house an electromechanical control system to limit the level of condensate within a drain pan of an air conditioning system. The condensate sensor enclosure comprises a control system compartment to receive an electromechanical control system therein, a cover to close the upper portion or open end of the control system compartment and a pair of hollow probe housings or protrusions each extending downwardly from the bottom of the control system compartment is operatively receive and house a corresponding electrically conductive sensor probe.

A pair of probe apertures is formed, through the lower portion of the control system compartment to receive a portion of the corresponding electrically conductive sensor probe extending upwardly through the corresponding hollow probe housing or protrusion.

A retainer engages and secures the electromechanical control system within the control system compartment.

Each electrically conductive sensor probe is secured in watertight relationship to the interior of the control system cabinet within a corresponding probe channel.

The electromechanical control system comprises state of the art circuitry and switching control to control the operation of a pump or similar device to limit the level of condensate with the drain pan of an air conditioning system. In addition, the electromechanical control system may also control operation of the air conditioning system.

When assembled, the control system compartment and the cover are secured to each other by a coupling assembly to enclose the electromechanical control system within a compartment cavity.

When installed, the condensation sensor enclosure is clamped or mounted to the side of the drain pan.

In operation, an impedance created by condensate is sensed between or across the electrically conductive sensor probes indicates a predetermined level of condensate within the drain pan. A microprocessor or similar control that includes logic or circuitry generates a condensate level control signal to either activate a pump or shut down the air conditioning system or both.

The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and object of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is an exploded perspective view of the condensate sensor enclosure of the present invention.

FIG. 2 is an exploded front view of the condensate sensor enclosure of the present invention.

FIG. 3 is a top view of the control system compartment and hollow probe protrusions of the condensate sensor enclosure of the present invention.

FIG. 4 is a perspective view of the control system compartment and hollow probe protrusions of the condensate sensor enclosure of the present invention.

FIG. 5 is a bottom view of the cover of the condensate sensor enclosure of the present invention.

FIG. 6 is a partial cross-sectional side view of a hollow probe housing or protrusion and corresponding electrically conductive sensor probe of the present invention.

FIG. 7 is a partial perspective view of the cover of the condensate sensor enclosure and of the present invention and the electromechanical control system.

FIG. 8 is a detailed side view of the upper electromechanical control system retainer and cover of the present invention.

Similar reference characters refer to similar parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIGS. 1 and 2, the present invention relates to a condensation sensor enclosure generally indicated as 10 to house an electromechanical control system to limit the level of condensate within a drain pan of an air conditioning system. The condensate sensor enclosure 10 comprises a control system compartment generally indicated as 12 to receive an electromechanical control system generally indicated as 14, a cover generally indicated as 16 to close the upper portion or open end of the control system compartment 12 and a pair of hollow probe housings or protrusions each generally indicated as 18 extending downwardly from the bottom of the control system compartment 12 is operatively receive and house a corresponding electrically conductive sensor probe generally indicated as 20.

The control system compartment 12 comprises a front and a rear compartment wall indicated as 22 and 24 respectively, a first and second compartment side wall indicated as 26 and 28 respectively, and a bottom compartment wall 30 to cooperatively form a compartment cavity 32 of the control system compartment 12 to house the electromechanical control system 14 therein.

A first lower coupling member generally as 34 extends outwardly from the upper portion of the first compartment side wall 26 and a second lower coupling member generally indicated as 36 extends outwardly from the upper portion of the second compartment side wall 28.

As best shown in FIGS. 3 and 4, the first lower coupling member 34 comprises an externally threaded substantially semi cylindrical protrusion 38 having a longitudinally disposed semicircular lower channel 40 including a plurality of conductor or wire engaging ridges 42 in the inner surface 44 thereof formed in the upper substantially flat surface 46 thereof; while, the second lower coupling member 36 comprises an externally threaded substantially semi cylindrical protrusion 48 having a recess 50 formed in the upper substantially flat surface 52 thereof.

The upper substantially flat surfaces 46 and 52 are substantially coplanar with the substantially flat upper surfaces 54, 56, 58 and 60 of the front compartment wall 22, rear compartment wall 24, first compartment side wall 26 and second compartment side wall 28 respectively. A substantially vertical substantially flat compression nut seal engaging surface 62 is formed at the base of externally threaded semi cylindrical protrusion 38 adjacent the external threads thereof and the externally threaded semi cylindrical protrusion 48 adjacent the external threads thereof on the first compartment side wall 26 and the second compartment wall 28 respectively to engage a compression nut seal 64.

As shown in FIG. 3, a lower electromechanical control system retainer comprising a substantially vertical PCB mounting rail or groove 66 is formed or attached to the inner surface of first compartment side wall 26 and the second compartment wall 28 form a seat to receive and secure the lower portion of the electromechanical control system 14 within the compartment cavity 32. In addition, a pair of substantially vertical PCB alignment members each indicated as 68 is formed or attached to the inner surface of the rear compartment wall 24 to engage the electromechanical control system 24 to maintain the electromechanical control system 14 in a substantially vertical position.

As shown in FIG. 3, a pair of probe apertures each indicated as 70 is formed through the bottom compartment wall 30 to receive a portion of the corresponding electrically conductive sensor probe 20 extending upwardly through the corresponding hollow probe housing or protrusion 18.

The cover 16 comprises a front and rear cover wall indicated as 72 and 74 respectively, a first and second cover side wall indicated as 76 and 78 respectively and a top cover wall 80 to cooperatively form the cover 14 including a cover cavity 82.

A first upper coupling member generally indicated as 84 extends outwardly from the lower portion of the first cover side wall 76 and a second upper coupling member generally indicated as 86 extends outwardly from the lower portion of the second cover side wall 78.

As best shown in FIG. 5, the first upper coupling member 84 comprises an externally threaded substantially semi cylindrical protrusion 88 having a longitudinally disposed semicircular upper channel 90 including a plurality of conductor or wire engaging ridges 91 formed in the inner surface 92 thereof formed in the lower substantially flat surface 94 thereof; while, the second upper coupling member 86 comprises an externally threaded substantially semi cylindrical protrusion 96 having a recess 98 formed in the lower substantially flat surface 100 thereof.

The lower substantially flat surface 94 and 100 are substantially coplanar with the substantially flat surfaces 102, 104, 106 and 108 of the front cover wall 72, rear cover wall 74, first cover side wall 76, and second cover side wall 78 respectively. A substantially vertical substantially flat compression nut seal engaging surface 110 is formed at the base of the externally threaded substantially semi cylindrical protrusion 88 adjacent the external threads thereof and the externally threaded substantially semi cylindrical protrusion 96 on the first cover side wall 76 and the second cover side wall 78 respectively to engage the compression nut seal 64 as described hereinafter.

An upper electromechanical control system retainer generally indicated as 112 to engage and secure the electromechanical control system 14 within the compartment cavity 32 of the control system compartment 12 as described hereinafter.

As best shown in FIG. 6, each hollow probe housing or protrusion 18 comprises a substantially cylindrical probe housing 114 having a lower stepped probe channel including a lower enlarged space or portion 116 and a upper reduced space or portion 118 cooperatively forming a limit or stop 120 to engage a portion of the corresponding sensor probe 20 and an upper probe channel 122 separated by an intermediate wall 124 having an aperture 126 formed therethrough concentrically aligned with the corresponding probe aperture 70 formed in the bottom compartment wall 30. A plurality of protective fins each indicated as 128 are formed on the outer surface of the substantially cylindrical probe housing 114.

As best shown in FIGS. 7 and 8, each electrically conductive sensor probe 20 comprises an upper substantially vertical shaft 130 and a lower probe element generally indicated as 132 including a reduced substantially circular intermediate disk or shelf 134 to engage the limit or stop 120 to limit the upward position of the electrically conductive sensor probe 20 within the lower enlarged space or portion 116 and to press a pliable O-ring or seal 136 into the upper upper space or portion 118 of the stepped probe channel and against the lower surface of the intermediate wall 124 to form a watertight seal between the interior of the compartment cavity 34 and the corresponding hollow probe housing or protrusion 18 and interior of the drain pan (not shown). The condensate sensing convex surface 138 of the lower probe element 132 is disposed within the corresponding lower space or portion 116 above the bottom of the substantially cylindrical probe housing 114.

Alternatively, the lower end of each hollow probe housing or protrusion 18 may comprise a diagonal surface 139 so that neither electrically conductive sensor probe 20 is entirely disposed therein so long as the lowest extent of each hollow probe housing or protrusion 18 is below or lower than the lowest extent of the corresponding electrically conductive sensor probe 20 to prevent either electrically conductive sensor probe 20 from engaging the bottom of the drain pan (not shown).

As shown in FIGS. 6 through 8, each electrically conductive sensor probe 20 is secured in watertight relationship to the compartment cavity 32 of the control system cabinet 12 within the corresponding lower stepped probe channel by locking palnut 140 engaging or resting on the inner surface of the bottom compartment wall 30.

As shown in FIGS. 1, 2, 7 and 8, the electromechanical control system 14 comprises state of the art circuitry including a microprocessor or a printed circuit board (PCB) 142 and a control switch device 144 such as a relay to control the operation of a pump or similar device (not shown) to limit the level of condensate within the drain pan (not shown) of an air conditioning system (not shown).

The electromechanical control system 14 is coupled to a power source (not shown) and the pump (not shown) by a plurality of conductors 146 within an outer protective sheath 147.

As best shown in FIG. 6, each electrically conductive sensor probe 20 is electrically coupled to the PCB 142 and circuitry by a corresponding electrically conductive element or member comprising an electrically conductive nickel plated steel clip generally indicated as 148 comprises a first leg 150 including a first and second contact point or surface indicated as 152 and 154 respectively disposed in vertical relationship to each other to engage the upper substantially vertical shaft 130 of the electrically conductive sensor probe 20 and a second leg 156 of the flexible material to engage and retain the lower portion of the PCB 142 therebetween. The vertically disposed first and second contact points or surfaces 152 and 154 improve or enhance the physical stability of the electrically conductive sensor probes 20. A PCB bias comprising an arcuate member or engaging finger 158 to bias the second leg 156 against the rear surface 160 of the PCB 142.

When assembled, the substantially flat surfaces 46, 52, 54, 56, 58 and 60 of the control system compartment 12 and the corresponding substantially flat surfaces 94, 100, 102, 104, 106 and 108 of the cover 16 engage each other to enclose the electromechanical control system 14 within the compartment cavity 32. An upper peripheral apron or lip 164 is formed on the edge portion of the substantially flat surfaces 102 and 104 of the front cover wall 72 and rear cover wall 74 of the cover 16.

So configured, the control system compartment 12 and the cover 14 are coupled or secured together by a coupling assembly. Specifically, the first lower coupling member 34 of the control system compartment 12 and the first upper coupling member 84 of the cover 16 cooperatively form a first coupler comprising a substantially cylindrical first coupler to receive a corresponding compression nut or fastener 166 to compress the corresponding compressor nut seal 64 against the corresponding substantially vertical substantially flat seal engaging surface 62. Similarly, the second lower coupling member 36 of the control system compartment 12 and the second upper coupling member 86 of the electromechanical control system 14 cooperatively form a second coupler comprising a substantially cylindrical second coupler to receive the corresponding compression nut or fastener 166 to compress the corresponding compression nut seal 64 against the corresponding substantially vertical substantially flat seal engaging surface 62. In other words, the first coupler and the second coupler form a coupling assembly to secure the control system compartment 12 and the cover 16 operatively together.

The conductors 146 and outer protective sheath 147 extend through the center opening of the compressor nut or fastener 166 on the first side of the condensation sensor enclosure 10 such that the outer protective sheath 142 and each of the conductors 146 are sandwiched or press-fitted by corresponding conductor or wire engaging ridges 42 and 91.

As shown in FIG. 8, the upper electromechanical control system retainers 112 comprises a substantially vertical slot 165 formed in an upper retainer member 167 to receive the upper portion of the PCB 142 of the upper electromechanical control system retainer 112 which in cooperation with the substantially vertical PCB mounting rail(s)/groove(s) 66 form an electronic control system retainer to secure the electromechanical control system retainer to secure the electromechanical control system 14 within the condensate sensor enclosure 10.

Also shown in FIG. 8, is a cable retention notch 169 formed on upper retainer member 167 to engage and secure the outer protective sheath 147 and the conductors 146 in place.

When installed on a drain pan (not shown), the condensation sensor enclosure 10 is clamped or mounted to the side of the drain pan (not shown) by a mounting member 168 disposed in spaced relationship relative to the rear compartment wall 24 to cooperatively form a mounting channel or groove 170 therebetween. A fastener or thumbscrew 172 extends through the mounting member 168 to secure the condensation sensor enclosure 10 in place on the drain pan (not shown). Of course, any number of fastening means will suffice.

Since the apron or lips 164 is formed above the uppermost extent or apex of the mounting groove or channel 170 and overhangs the upper surfaces of the control system compartment 12 so that condensate will not enter the compartment cavity 32.

In operation, the condensate sensing element or probes 20 detects when the condensate level within the condensate collector or drain pan (not shown) reaches the predetermined condensate level. The impedance between the condensate sensing element or probes 20 may be sampled multiple times during a sampling period. If the condensate in the condensate collector or drain pan (not shown) has reached the predetermined condensate level the impedance across the electrically conductive sensor probes 20 completes the circuit to generate a condensate sensor signal fed to the electromechanical control system 14 or similar control that includes logic or circuitry to generate the condensate level control signal fed to a pump (not shown) and/or the air handler control system (not shown).

After the air conditioning system has shut down or pump activated, the electrically conductive sensor probes 20 continue to monitor the condensate level in the condensate collector or drain pan (not shown). When condensate in the condensate collector or drain pan (not shown) is no longer detected by the electrically conductive sensor probes 20, a second or no-condensate signal may be sent to the electromechanical control system 14 to deactivate the pump (not shown) and/or turn on the air conditioning system.

Of course, upon detection of condensate, the electromechanical control system 14 may operate an external alarm, external monitoring system, digital control system or other peripheral equipment or device.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. 

What is claimed is:
 1. A condensate sensor enclosure to house an electromechanical control system to limit the level of condensate within a drain pan of an air conditioning system comprising a control system compartment and cover coupled together by a coupling assembly to enclose the electromechanical control system therein and at least one probe housing extending downwardly from the bottom portion of said control system compartment to operatively receive and house at least a portion of a pair of electrically conductive sensor probes operatively coupled to the electromechanical control system to sense when the condensate within the drain pan reaches a predetermined level.
 2. The condensate sensor of claim 1 wherein said control system compartment comprises a front and a rear compartment wall, a first and second compartment side wall, and a bottom compartment wall to cooperatively form a compartment cavity to house the electromechanical control system therein and said cover comprises a front and rear cover wall, a first and second cover side wall and a top cover wall.
 3. The condensate sensor enclosure of claim 2 wherein said coupling assembly comprises a first coupler formed on one side of said condensate sensor enclosure and a second coupler formed on the opposite side of said condensate sensor enclosure.
 4. The condensate sensor enclosure of claim 3 wherein said first coupler comprises a first lower coupling member extending outwardly from said first compartment side wall and a first upper coupling member extending outwardly from said first cover side wall disposed to engage each other and said second coupler comprises a second lower coupling member extending outwardly from said second compartment side wall and a second upper coupling member extending outwardly from said second cover side wall disposed to engage each other.
 5. The condensate sensor enclosure of claim 4 wherein said first lower coupling member comprises an externally threaded substantially semi cylindrical protrusion and said the upper coupling member comprises an externally threaded substantially semi cylindrical protrusion to cooperatively for an externally threaded substantially cylindrical member to receive an internally threaded fastener, and said second lower coupling member comprises an externally threaded substantially semi cylindrical protrusion and second upper coupling member comprises an externally threaded substantially semi cylindrical protrusion to cooperatively for an externally threaded substantially cylindrical member to receive an internally threaded fastener.
 6. The condensate sensor enclosure of claim 5 wherein said first lower coupling member further comprises a longitudinally disposed lower channel including a plurality of conductor or wire engaging ridges formed therein and said first upper coupling member further comprises a longitudinally disposed channel including a plurality of conductor or wire engaging ridges formed therein to engage conductors coupled to the electromechanical control system to secure the conductors to said condensate sensor enclosure.
 7. The condensate sensor enclosure of claim 2 wherein a coupling assembly comprises the first lower coupling member on said control system compartment and the first upper coupling member on said cover cooperatively forming a first coupler comprising a substantially cylindrical first coupler to receive a corresponding fastener to compress a corresponding compressor nut seal against said control system compartment and said cover and a second lower coupling member on said cover cooperatively forming a second coupler comprising a substantially cylindrical second coupler to receive a corresponding compression nut or fastener to compress a corresponding compression nut seal against said control system compartment and said cover.
 8. The condensate sensor enclosure of claim 1 further comprising an upper electromechanical control system retainer formed on said cover to engage said electromechanical control system.
 9. The condensate sensor enclosure of claim 10 wherein said cover further comprises a cable retainer formed thereon to engage and secure the conductors in place.
 10. The condensate sensor enclosure of claim 1 further comprises a mounting member disposed in spaced relationship relative to said rear compartment wall to cooperatively form a mounting channel or groove therebetween to engage a wall of the drain pan.
 11. The condensate sensor enclosure of claim 10 wherein a peripheral ledge is formed about the upper portion of said control system compartment and disposed above the uppermost extent of said mounting groove or channel such that condensate can not enter said compartment cavity.
 12. The condensate sensor enclosure of claim 10 further includes a fastener extending through said mounting member to secure said condensation sensor enclosure in place on the drain pan.
 13. The condensate sensor enclosure of claim 11 further comprising a lower electromechanical control system retainer comprising a groove formed on the inner surface of said first compartment side wall and said second compartment side wall to form a seat to receive and secure the lower portion of the electromechanical control system within said compartment cavity.
 14. The condensate sensor enclosure of claim 13 further comprising a pair of alignment members formed on the inner surface of said rear compartment wall to engage the electromechanical control system to maintain the electromechanical control system in position.
 15. The condensate sensor enclosure of claim 14 further comprising an upper electromechanical control system retainer formed thereon to engage said electromechanical control system.
 16. The condensate sensor enclosure of claim 1 including a pair of probe housings each comprising probe housing having a lower stepped probe channel including a lower enlarged space or portion and an upper reduced space or portion cooperatively forming a limit or stop to engage a portion of said corresponding electrically conductive sensor probe and an upper probe channel separated by an intermediate wall having an aperture formed therethrough concentrically aligned with the corresponding probe aperture formed in said bottom compartment wall.
 17. The condensate sensor enclosure of claim 15 wherein each electrically conductive sensor probe comprises an upper substantially vertical shaft and a lower probe element including a reduced substantially circular intermediate disk or shelf to engage said limit or stop to limit the upward position of each electrically conductive sensor probe within said lower enlarged space or portion and to press a seal into said upper space or portion of said stepped probe channel and against said lower surface of said intermediate wall to form a watertight seal between said compartment cavity and said corresponding hollow probe housing or protrusion.
 18. The condensate sensor enclosure of claim 17 wherein a condensate sensing convex surface is formed on said lower probe element and disposed within said corresponding lower space or portion above the bottom of said substantially cylindrical probe housing.
 19. The condensate sensor enclosure of claim 16 wherein lower end of each said hollow probe housing or protrusion comprises a diagonal surface so that said corresponding electrically conductive sensor probe entirely disposed therein so long as the lowest extent of each hollow probe housing or protrusion is below or lower than the lowest extend of said corresponding electrically conductive sensor probe to prevent either said electrically conductive sensor probe from engaging the bottom of the drain pan.
 20. The condensate sensor enclosure of claim 1 wherein each said electrically conductive sensor probe is electrically coupled to the electromechanical control system by a corresponding electrically conductive member disposed to engage said corresponding electrically conductive sensor probe.
 21. The condensate sensor enclosure of claim 20 wherein each said electrically conductive member comprises a first and second contact to engage the electromechanical control system at two points.
 22. The condensate sensor enclosure of claim 1 wherein each said electrically conductive sensor probe is electrically coupled to the electromechanical control system by a corresponding electrically conductive member comprising an electrically conductive clip including a first leg having a first and second contact surface disposed in vertical relationship to each other to engage the said corresponding electrically conductive sensor probe and a second leg of the flexible material to engage and retain the lower portion of the electromechanical control system therebetween.
 23. The condensate sensor enclosure of claim 22 wherein each said electrically conductive clip further includes a bias comprising an arcuate member or engaging finger to bias said second leg against said electromechanical control system. 